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Old 02-22-2012, 10:34 AM   #1
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Has anyone done a 5.9 magnum swap?

I came across a great deal on a 96 ram with a 5.9. Its a complete running truck. I am thinking about buying it so I can yank out the 4.0/32rh and swap in the 5.9.
I know that AA makes the motor mounts. My main concern is the wiring. I refuse to send out both harnesses and pay a shop $700 to make it up for me. I guess the first step will be to pick up the FSM for my jeep and for the 96 ram.
I was just hoping that someone on here has done the swap themselves and could provide some insight.

My jeep is a 97 so I think that the PCM from the 96 ram will work so that I can retain all of my gauges.

On a side note I will have a 4.0 with 142k miles and a 32rh with 120k miles for sale once this swap commences.

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Old 02-22-2012, 10:55 AM   #2
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Old 02-22-2012, 10:57 AM   #3
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Thanks for the links. From what I understand its the same swap just a little more displacement.
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Old 02-22-2012, 01:19 PM   #4
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Yeah, if I was gonna do a V8 swap the 5.9 would be my choice (though I'm not sure about how I'd find an 06 or newer engine!)
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Old 02-22-2012, 02:19 PM   #5
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The 5.2 is very similar to the 5.9, so anything on a 5.2 swap should help getting in the right direction. I'm a fan of the Magnum motor, but I will say that is a big heavy engine and not always the best of swap choices for a Jeep.
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Old 02-22-2012, 02:33 PM   #6
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What does the law say about engine swaps?
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Old 02-22-2012, 03:00 PM   #7
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Varies by state. Here in Kentucky, pretty much do whatever because there are no vehicle inspections outside of verification of VIN.

PA, it actually varies by county. What it boils down to though is if it passes emissions.

PA DEP I/M - Emission Test Calculator
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Old 02-22-2012, 03:43 PM   #8
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Any vehiclein PA that is 15 years old or older is eleigable for classic tags. With classic tags a vehicle is emmisions exempt. I had an 86 ranger a few years ago with a built 351w.
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Old 02-22-2012, 06:05 PM   #9
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You need to make sure they both have the same obd1 or obd2 if they are not the same it won't work from what I'm told I'm looking to do the same swap also was told to try to find the same year donor as existing to make swap easier.
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Old 02-22-2012, 06:11 PM   #10
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It is my understanding that everything 95 + is obdII the ram is a 96 and my TJ is an early 97 built in May or June of 96.

I think I will be okay. I am currently running a 98 tj PCM without issue because of the auto tranny swap I did last summer.
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Old 02-22-2012, 09:37 PM   #11
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They show the swap in the new TJ Wrangler mag. It only put 190hp to the rear wheels! IMO that swap is a joke for the engine size and the amount of weight it will add the the Jeep. Save up and get an LS1, it would be a better swap in the long run.
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Old 02-22-2012, 10:30 PM   #12
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1997 tj 4.0 specs are 181hp @4600 and 222tq @2800 engine weight is 515lbs

1996 ram 5.9 specs are 230hp @ 4000 and 330tq @3300 engine weight is 650lbs

I'm looking at 50 more HP at 600 less rpm and over 100 ft.lbs of extra torque. It only weighs 135lbs more than my 4.0. If stick a 135 lb person in your jeep do you nitice a huge difference in performance or handeling? I doubt it.
It has nothing to do with saving up. This engine provides more than enough power compared to the 4.0 I can use my stock gages, my np231 TC and the wiring is fairly simple compered to other swaps.
I am picking up this 96 ram for 1k. Do you really think that its worth an extra 3k to 5k for me to do an ls1 swap. I would have to buy custom gauges, a $500 + adapter for my transfer case and I would not be able to use my current driveshafts either.
My plans are to have less than $500 wrapped up into this swap after I sell the 4.0/32rh and what ever is left of the ram when I'm done with it.
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Old 02-22-2012, 10:36 PM   #13
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Like the Magnum swap idea but you can gain more hp and tq by stroking a 4.0. A 4.6 stroker is what I'll do when the time comes.

It does look cool in under the hood plus the factory gauges working is nice.
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Old 02-22-2012, 10:41 PM   #14
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I thought about a stroker but It will cost way more and the jeep will be off the road longer. I plan to do the 5.9 swap over the course of 2 or 3 weekends.
Plus I love the sound of a v8 with flomasters
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Old 02-23-2012, 12:29 AM   #15
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Not trying to change your plans but a stroker can be done under $2k if you build it yourself. That's with a new rotating assembly, cam kit and a ported head.
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Old 02-23-2012, 01:16 AM   #16
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When all is said and done i should have less than $500 into this swap. For future replys please keep in mind im not doing a stroker or an ls1, im doing a 5.9 magnum. If anyone here has done this and has any tips to offer on the wiring i would appreciate it.
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Old 02-23-2012, 12:26 PM   #17
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The wiring for a 4.0L and 5.2L or 5.9L are identicle save for 1 or two wires (and of course a few more injectors). Even the PCM pin locations are identicle, which means any info you find on a 4.0L will almost certainly apply to a v8 magnum of a similar year.

Post # 4 has some info:

5.2 Swap Help!!! Electrical Wiring issue - JeepForum.com

Nick here might be able to assist:

Info on a 5.2L or 5.9L conversion into a TJ (my experience) - JeepsUnlimited.com Forums

Found this as well.

Follow each of the 32 wires and compare the two harnesses. The Gray Jeep plug runs into the engine compartment and over to the Power Distribution Center. Two wires were removed from the Dodge harness added to the Jeep Gray plug for the Leak Detection Pump. Be prepared to fabricate a bracket for the LDP and the second charcoal canister. The two smaller plugs (C103, & C104) in the Jeep “Gray” harness will be spliced in to replace the large, square White plug that goes into the PDC. The truck Gray plug must be carefully removed and the wires spliced into C103 & C104 from the Jeep.
The V8, Black and White plugs will need to be checked against the Jeep schematics. The large power wire from the Alternator will need to be spliced into the B+ terminal at the Power Distribution Center with a 150A fuse. Fuel pump, VSS, Reverse light, and 4WD light wiring will be used from the TJ and spliced into the truck harness.
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Old 02-23-2012, 08:35 PM   #18
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Yah if your getting it that cheap, and the swap is that easy id go with the 5.9! I wonder how that engine reacts to a cam and header swap. That would be easy with it out of the truck.
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Old 02-24-2012, 10:10 AM   #19
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Quote:
Originally Posted by Abnmarine View Post
Like the Magnum swap idea but you can gain more hp and tq by stroking a 4.0. A 4.6 stroker is what I'll do when the time comes.

It does look cool in under the hood plus the factory gauges working is nice.
You would have to put more than $2k in a 4.6 stroker to get 330 lb ft tq. But it would easily pass the 230 HP mark.
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Old 02-24-2012, 01:45 PM   #20
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Quote:
Originally Posted by XJTJ View Post
You would have to put more than $2k in a 4.6 stroker to get 330 lb ft tq. But it would easily pass the 230 HP mark.
325 ft tq can be achieved and has been proven with just the rotating assembly, cam and a 3 angle valve job. I'm sure properly porting the head could provide another 10 ft tq.
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Old 02-24-2012, 05:44 PM   #21
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These guys might have some useful stuff The Novak Catalog Gateway have fun.
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Old 02-24-2012, 05:48 PM   #22
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Thanks for the links and ideas guys. I will keep this thread updated when I dive into this project. I'm hoping to pick up the ram in the next week or 2. Having to shell out 1k for taxes this year set me back a little bit
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Old 03-14-2012, 06:07 PM   #23
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Old 04-12-2013, 01:44 PM   #24
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watching closely as my 2.5 just is dead?

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